Lincoln Electric INVERTEC SVM101-B manual

INVERTEC V300-I SVM101-B January , 2007 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated a[...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I st[...]

SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufactu[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ?[...]

V300-I v v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . .[...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Section A T echnical Specifications ..[...]

V300-I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION A-2 TECHNICAL SPECIFICA TIONS - V300-I (K1363-8, K1363-9) Height W idth Depth W eight 18.7 in. 10.8 in. 22.2 in. 64 lbs. 475 mm 274 mm 564 mm 29 Kg PHYS[...]

V300-I INST ALLA TION A-3 A-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. . . . . Do not touch electrically live parts. Only qualified persons should install, use or service [...]

V300-I INST ALLA TION A-4 A-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER INPUT CONNECTION Connect terminal marked to earth ground per any existing local or national electrical codes. Single Phase Input Connect the s[...]

V300-I INST ALLA TION A-5 A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-9 GMA Connection Instructions (Not applicable to machines with only 42V Aux.) 1. T urn the Invertec power switch “off”. 2. Connect the K596 o[...]

3 . Slide the copper tube into the brass plug. 4. Insert cable into copper tube. 5. T ighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening. 6. Slide rubber boot over brass plug. The rubber boot must be positioned to compl[...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Section B Operating Instructions...........[...]

V300-I OPERA TION B-2 B-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS DUTY CYCLE The Invertec is rated at 300 amps, 60% duty cycle for 3 phase inputs (based on a 10 minute cycle). It is also rated a[...]

V300-I OPERA TION B-3 B-3 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T O C Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC MODE SWITCH GT A W Optimized for both scratch start and Hi- Freq kit use. CC SOFT Best for EXX18[...]

V300-I OPERA TION B-4 B-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC METER POLARITY SWITCH The wire feeder polarity switch is located at the rear of the machine. The switch provides a work connection for wire feeder voltm[...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Options/Accessories ..............[...]

V300-I ACCESSORIES C-2 C-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONS / ACCESSORIES CABLE PLUGS Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to welding cable to provide quick disconnect from machine. Cable [...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D Input Filter Capacitor Discharge Pr[...]

V300-I MAINTENANCE D-2 D-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Locate the two capacitor terminals (large hex head capscrews)shown in Figure D.1. 6. Use electrically insulated gloves and insulated pli- ers. Hold [...]

V300-I MAINTENANCE D-3 D-3 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T O C Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC OVERLOAD PROTECTION T he machine is electrically protected from producing high output currents.[...]

V300-I MAINTENANCE D-4 D-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.2 — LOCA TION OF MAINTENANCE COMPONENTS. ITEM COMPONENT QTY , NO. PC BOARDS CONTROL 1 1 DRIVER 1 2 PROTECTION 1 3 SWITCH 2 7 POWER 1 10 INPU[...]

Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Power Supply Operation ...........................................................[...]

V300-I THEOR Y OF OPERA TION INPUT LINE VOL T AGE & AUXILIAR Y TRANSFORMER The V300-I can be connected for a variety of three phase or single phase input voltages. Power is applied through the Line Switch to the Input Rectifier and the Auxiliary T ransformer . The Reconnect Panel has switches to select high or low operating voltage. The “A”[...]

V300-I THEOR Y OF OPERA TION PRECHARGE & PROTECTION CIRCUITS The DC voltage from the Input Rectifier is applied to the Driver Board to begin charging the Switch Board capacitors at a slow rate. When the pre-charge level is achieved, the input relays close, applying the full DC voltage to the capacitors. Depending on the Code Number of the machi[...]

V300-I THEOR Y OF OPERA TION SWITCH BOARDS The Switch Boards contain the the Field Effect T ransistors (FET s) which, when switched ON, supply power to the primary windings of the main transformer . Each Switch Board powers a separate, oppositely wound primary winding. The opposite direction of cur - rent flow in those windings and a slight of fset[...]

V300-I THEOR Y OF OPERA TION OUTPUT AND CONTROL CIRCUITS The AC output of the transformer is changed to DC by the Output Rectifier . The Output Choke between the negative side of the rectifier and the negative output stud provides the necessary filtering for DC welding. The two smaller chokes and their series diodes are the OCV boost circuit used t[...]

V300-I THEOR Y OF OPERA TION An FET is a type of transistor . FET s are semiconduc- tors well suited for high-frequency switching because they are capable of going from full off to full on much more quicklfy than other types of semi-conductors. Drawing A above shows an FET in a passive mode. There is no gate signal, zero volts relative to the sourc[...]

V300-I THEOR Y OF OPERA TION E-7 E-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. MAXIMUM OUTPUT By holdin[...]

V300-I THEOR Y OF OPERA TION E-8 E-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of c[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V300-I Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - Tr oubleshooting & Repair Section ........................................................................Section F How to Use T roubleshooting Guide ....................[...]

HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safet[...]

V300-I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connectio[...]

V300-I TROUBLESHOOTING & REP AIR INPUT FIL TER CAP ACITOR CONDITION- ING Capacitor conditioning may be required if the machine will not produce output after power is applied and the following two conditions exist:: The machine is connected to a supply of 380 v .a.c. or higher and Power has not been applied to the machine for an extended period [...]

Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-5 F-5 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTIO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMEN[...]

Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-7 F-7 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this [...]

Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-8 F-8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMEN[...]

V300-I NOTES F-10 F-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

V300-I TROUBLESHOOTING & REP AIR F-11 F-11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

V300-I TROUBLESHOOTING & REP AIR INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE 1. T urn off input power or disconnect input power lines. 2. Remove 14 5/16” hex head screws from side and top of machine (6 screws on each side and 2 screws on top) and remove wrap-around machine cover . 3. Be careful not to make contact with the capacitor terminal[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed t[...]

V300-I F-14 F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn Input Power Switch OFF 2. Perform Input Capacitor Discharge test as described in the Maintenance Section. 3[...]

V300-I F-15 F-15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR FIGURE F .3 – CONTROL BOARD TEST POINTS OUTPUT PILOT CIRCUIT TEST (cont.) 7. Measure voltage fr om Lead #210 (J2/Pin 4) to Lead #[...]

V300-I NOTES F-16 F-16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

V300-I TROUBLESHOOTING & REP AIR F-17 F-17 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

V300-I TROUBLESHOOTING & REP AIR F-18 F-18 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TES T PROCEDURE 1. TURN POWER SWITCH OFF 2. Remove sheetmetal wraparound.[...]

V300-I TROUBLESHOOTING & REP AIR F-19 F-19 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 8. With power OFF , di[...]

V300-I TROUBLESHOOTING & REP AIR F-20 F-20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 12. Open S4 and T urn Power OFF 13. Move probes to test between leads 306 (+) an[...]

V300-I TROUBLESHOOTING & REP AIR F-21 F-21 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

V300-I TROUBLESHOOTING & REP AIR F-22 F-22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TIC CAP ACITOR TEST TEST PROCEDURE: 1. With Output T erminal Switch S4 in REMOTE (OFF) position, turn Power Switch ON. 2. T es[...]

V300-I TROUBLESHOOTING & REP AIR F-23 F-23 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .7 - SWITCH BOARD TEST POINTS L8 604- 1 L8604-1 SW I T CH SWITCH 9 9R W 12 WR 401/ 403 1/ 8 4/ 5 402/ 404 12 CAP ACITOR BA[...]

V300-I NOTES F-24 F-24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

V300-I TROUBLESHOOTING & REP AIR F-25 F-25 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

V300-I TROUBLESHOOTING & REP AIR F-26 F-26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD TEST (cont.) TEST PROCEDURE 1. Disconnect power to the machine and perform Input Filter Capacitor Discharge Procedure [...]

V300-I TROUBLESHOOTING & REP AIR F-27 F-27 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC SWITCH BOARD TEST (CONT .) Apply Positive Apply Negative T est Probe to T[...]

V300-I TROUBLESHOOTING & REP AIR F-28 F-28 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD TEST (CONT .) Apply Positive Apply Negative T est Prove to T est Probe to T erminal T erminal T est Result Conclusion [...]

V300-I TROUBLESHOOTING & REP AIR F-29 F-29 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

V300-I TROUBLESHOOTING & REP AIR 5. T est for 25 ohms resistance from lead 401 to termi- nal 12 on Switch Board. a. If 25 ohms is measured, Resistor R4 is OK. b. If 30 ohms or more is measured, Resistor R4 is faulty and must be replaced. c. If 20 ohms or less is measured, Resistor R4 is faulty and must be replaced. 6. Repeat same procedures to [...]

V300-I TROUBLESHOOTING & REP AIR F-31 F-31 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This procedur e will determine if the Output Diodes are defective. MA TERIALS NEEDED Vo lt/Ohm Meter (multi-meter)[...]

V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Locate the Output T erminals on front panel. 2. Remove any cables from Output T erminals. 3. T est for more than 200 ohms resistance between positive and negative Output T erminals: positive meter lead to the positive terminal, negative meter lead to the negative terminal. NOTE: Polarity of tes[...]

V300-I TROUBLESHOOTING & REP AIR TEST DESCRIPTION This procedur e will determine if the Input Rectifier is defective. MA TERIALS NEEDED ANALOG Vo lt/Ohm Meter (multi-meter) Misc. Hand T ools Wiring Diagram (Section G) F-33 F-33 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to[...]

V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Perform Input Filter Capacitor Discharge Procedure as detailed in this section. 2. Locate Input Rectifier (Component D-13). 3. Locate leads needed to perform tests shown in Figure F .1 1. 4. Use ohmmeter to perform tests shown in T able F .5. Replace the Inpit Rectiferif readings are not as ind[...]

V300-I TROUBLESHOOTING & REP AIR F-35 F-35 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVERCURRENT PROTECTION CURRENT TRIGGER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory traine[...]

V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Perform Input Filter Capacitor Discharge Procedure detailed in this section. 2. Remove front panel from machine to access Control Board. 3. Arrange wires so there is ample room to work on the board. 4. T urn main power ON. 5. T est for 15 VDC between leads 302 and 275D. a. If 15 VDC is present,[...]

V300-I TROUBLESHOOTING & REP AIR 6. T urn main power OFF . 7. Perform Input Filter Capacitor Discharge Procedure detailed in this section. T est resistance of the Black and White leads from 1J3 and 2J3 to the shunt. See Figure F .14. a. If zero ohms resistance (continuity) is shown, test is OK. b. If resistance of any value is shown, check wire[...]

V300-I TROUBLESHOOTING & REP AIR F-38 F-38 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVER VOL T AGE PROTECTION DC TRIGGER CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory [...]

V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge procedure detailed in Maintenance section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests: (Do not disconnect from wiring harness.) • Control Board • Protection Board •[...]

V300-I TROUBLESHOOTING & REP AIR 7. T est for 0 VDC between leads 31 1 and 313 on Protection Board. a. If 0-1 VDC is present, the Protection Board is OK. Go to step 8. b. If 15 VDC is present, go to step 1 1. F-40 F-40 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master T[...]

V300-I TROUBLESHOOTING & REP AIR 8. T est for 15 VDC supply voltage between leads 302 and 275D on Power Board. a. If 15 VDC is present, test is OK. Go to step 9. b. If 15 VDC is not present, the Power Board may be faulty . Check for 18 V AC input voltage at lead 501 and 504 (J7). If 18 V AC is present the Power Board is faulty and must be repla[...]

V300-I TROUBLESHOOTING & REP AIR 11 . If 15 VDC is present at step 7, test Capacitor volt- ages using leads shown in Figure F .19. If voltage does not match table, check reconnect switches for proper operation and proper position for voltage applied. Perform Capacitor Balance T ests. F-42 F-42 Return to Section TOC Return to Section TOC Return [...]

V300-I TROUBLESHOOTING & REP AIR F-43 F-43 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION AC TRIGGER CIRCUIT W ARNING Service and repair should be performed by only Lincoln Electric factory trained pers[...]

V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in this section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests. (Do not disconnect from wiring harness.) • Power Board • Control Board NOTE: Do not [...]

V300-I TROUBLESHOOTING & REP AIR 4. Locate the Auxiliary T ransformer T1 and leads used for test. See Figure F .21. 5. T urn main power ON. 6. T est Auxiliary T ransformer voltage for 24 V AC between leads 503 and 212D. See Figure F .21. a. If 24 V AC is present, transformer is OK. Go to step 7. b. If 0 V AC is present, test input voltage to Au[...]

V300-I NOTES F-46 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

V300-I TROUBLESHOOTING & REP AIR F-47 F-47 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized r[...]

V300-I TROUBLESHOOTING & REP AIR . TEST PROCEDURE NOTE: Perform T est A before disassembling the unit T est A 1. T urn main power OFF . 2. Position yourself at Switch Board area of the machine (near Case Back) so as to hear the oper- ation of the control relays. 3. T urn main power ON. 4. Listen for control relays to operate (audible click of c[...]

V300-I TROUBLESHOOTING & REP AIR 6. T est for 18 V AC input from Auxiliary T ransformer between leads 504 and 501 (J7-pin 5 & pin6) on Power Board. If 18 V AC is not correct, check the 3 amp fuse, the Auxiliary T ransformer and associated wires. 7. T est for 15 VDC output between leads 275D (-) and 302 (+) (J6-pin1 & pin 6) on Power Boa[...]

V300-I TROUBLESHOOTING & REP AIR F-50 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST (cont.) FIGURE F .24 - SIMPLIFIED TRIGGER CICUIT FROM PROTECTION BOARD OVERVOLTAGE PWM OUTPUTS TO POWER BOARD 7J6 [...]

V300-I TROUBLESHOOTING & REP AIR F-51 F-51 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory tra[...]

V300-I TROUBLESHOOTING & REP AIR PROCEDURE NOTE: When replacing capacitors, remove the entire FET Heat Sink Assembly as a unit. Remove and reassemble one side at a time, using the other side as a model to insure that all parts are reinstalled prop erly 1. Perform the Input Filter Capacitor Discharge Procedure. 2. Remove the two 3/8” hex nuts [...]

V300-I TROUBLESHOOTING & REP AIR 4. Remove the two 1/4-28 hex head bolts that hold the Capacitor to the PC board. See Figure F .27. 5. Loosen the set screw of the Capacitor clamp ring and remove the Capacitor from the clamp ring. See Figure F .28. F-53 F-53 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC [...]

V300-I TROUBLESHOOTING & REP AIR NOTE: Proper capacitor polarity must be noted when attaching the capacitor to the Switch Board assembly . 6. Install the new Capacitor and tighten the two bolts to a torque of 55 inch-pounds (6 Nm). Hand tight- en first, then tighten the bolts in increments of 10 inch-pounds, alternating between the two. See Fig[...]

V300-I TROUBLESHOOTING & REP AIR F-55 F-55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory tr[...]

V300-I TROUBLESHOOTING & REP AIR NOTE: If a test indicates that a Switch Board is defec- tive, unless their part number is L10958-[ ] both Switch Boards must be replaced at the same time. In addition to replacing the Switch Boards, Capacitors C1 and C2 (plus C14 and C15 on 575 V AC models) must also be replaced if the following conditions exist[...]

V300-I TROUBLESHOOTING & REP AIR F-57 F-57 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST AFTER SWITCH BOARD OR CAP ACIT OR REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory[...]

B300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Dis-charge proce- dure detailed in Mainten-ance section.. 3. Connect a shorting conductor across terminals 14 and 53 of Protection Board. 4. Set an ohmmeter to X1000 range and place probes on terminals 9 (+) and 12 (-) of one Switch Board[...]

V300-I TROUBLESHOOTING & REP AIR F-59 F-59 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC OUTPUT DIODE REPLACEMENT PROCEDURE W ARNING Service and repair should be [...]

V300-I TROUBLESHOOTING & REP AIR PROCEDURE (Paralleled IndividualDiodes) 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors. See Switch Board Removal and Replacement procedure 4. Detach the fan shroud to gai[...]

V300-I TROUBLESHOOTING & REP AIR PROCEDURE (Diode Modules) 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors. See Switch Board Removal and Replacement procedure 4. Detach the fan shroud to gain access to th[...]

V300-I TROUBLESHOOTING & REP AIR F-62 F-62 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V300-I Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...............................................................................................Section G Wiring Diagram (L8657 for Code 9826) . . . . . . . . . . . [...]

ELECTRICAL DIAGRAMS G-2 V300-I WIRING DIAGRAM - ENTIRE MACHINE - CODE 9826 (L8657) G-2 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to[...]

ELECTRICAL DIAGRAMS G-3 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 9827 (L8938) L G-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to[...]

ELECTRICAL DIAGRAMS G-4 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10036 (L9299) G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to [...]

ELECTRICAL DIAGRAMS G-5 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10037 (L9300) G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to [...]

ELECTRICAL DIAGRAMS G-6 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10132 (L9567) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to [...]

ELECTRICAL DIAGRAMS G-7 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10133 (L9568) G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to [...]

ELECTRICAL DIAGRAMS G-8 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10258 (L10189) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to[...]

ELECTRICAL DIAGRAMS G-9 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10336, 10450 (L10205) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Re[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-10 V300-I SCHEMA TIC - ENTIRE MACHINE G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. BOARD [...]

ELECTRICAL DIAGRAMS G-11 V300-I SCHEMA TIC - DRIVER PC BOARD - (S20216) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-13 V300-I SCHEMA TIC - DRIVER PC BOARD (S20799) G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-15 V300-I SCHEMA TIC - SWITCH PC BOARD (L8440) G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-17 V300-I SCHEMA TIC - SWITCH PC BOARD (L10956) G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-19 V300-I SCHEMA TIC - CONTROL PC BOARD (G2525) G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-21 V300-I G-21 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Maste[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-22 V300-I SCHEMA TIC - PROTECTION PC BOARD (M16097) G-22 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]

ELECTRICAL DIAGRAMS G-24 V300-I SCHEMA TIC - POWER PC BOARD (M16018) G-24 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troubl[...]